Tray and packing apparatus

ABSTRACT

A tray includes: an outer sheet made of a cardboard sheet; at least one intermediate sheet wrapped in the outer sheet, each intermediate sheet being made of a cardboard sheet; and fastening means. The outer sheet includes: a bottom wall; a first lateral wall connected to the bottom wall by a first fold line; a second lateral wall connected to the bottom wall by a second fold line; a first upper wall connected to the first lateral wall by a third fold line parallel to the first fold line; and a second upper wall connected to the second lateral wall by a fourth fold line parallel to the second fold line. The fastening means fastens the first upper wall and the second upper wall.

TECHNICAL FIELD

The present invention relates to a tray and a packing apparatus.

BACKGROUND ART

A packing apparatus disclosed in PTL 1 described below includes a tray (2A). The tray (2A) is a laminate formed of plate bodies (21A, 22A, 23A, and 24A) made of cardboard sheets. The plate bodies (21A, 22A, 23A, and 24A) are bonded together by a bonding material.

CITATION LIST Patent Literature

[PTL 1] Japanese Patent Application Publication No. H09-131569

SUMMARY OF INVENTION Technical Problem

The feature in PTL 1 has the following problems when logistics transportation and freight handling are carried out. When the bonding between the plate bodies (21A, 22A, 23A, and 24A) is weak, there is a fear that bonding sections may peel apart from each other. In particular, there is a fear of strength poverty when objects to be packed are heavy products. There is a fear that the bonding sections of the plate bodies (21A, 22A, 23A, and 24A) may peel apart from each other, and the tray (2A) may deform. As a result, there is a fear that the objects to be packed, that is, the products may come in contact with each other and become damaged.

The present invention has been made in order to solve the abovementioned problems, and an object thereof is to provide a tray that can reliably protect objects to be packed when the logistics transportation or the freight handling is carried out, and a packing apparatus including the tray.

Solution to Problem

A tray according to the present invention includes: an outer sheet made of a cardboard sheet; at least one intermediate sheet wrapped in the outer sheet, each intermediate sheet being made of a cardboard sheet; and fastening means. The outer sheet includes: a bottom wall; a first lateral wall connected to the bottom wall by a first fold line; a second lateral wall connected to the bottom wall by a second fold line; a first upper wall connected to the first lateral wall by a third fold line parallel to the first fold line; and a second upper wall connected to the second lateral wall by a fourth fold line parallel to the second fold line. The fastening means is configured to fasten the first upper wall and the second upper wall.

A packing apparatus according to the present invention includes the tray.

Advantageous Effects of Invention

According to the present invention, the objects to be packed can be reliably protected when the logistics transportation or the freight handling is carried out.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view illustrating a tray of Embodiment 1.

FIG. 2 is a developed view of an outer sheet included in the tray of Embodiment 1.

FIG. 3 is a perspective view illustrating one of intermediate sheets included in the tray of Embodiment 1.

FIG. 4 is a perspective view illustrating a state in which the tray 1 of Embodiment is being assembled.

FIG. 5 is a plan view illustrating a state in which products are fitted in recessed portions of the tray of Embodiment 1.

FIG. 6 is a cross-sectional side elevation view illustrating, a state in which products are fitted in the recessed portions of the tray of Embodiment 1.

FIG. 7 is an exploded perspective view of a packing apparatus including the tray of Embodiment 1.

FIG. 8 is a perspective view of a state in which the packing apparatus illustrated in FIG. 7 is assembled.

FIG. 9 is a schematic cross-sectional view of an inside of the packing apparatus illustrated in FIG. 7 and FIG. 8.

FIG. 10 is a perspective view illustrating a tray of Embodiment 2.

FIG. 11 is a developed view of an outer sheet included in the tray of Embodiment 2.

FIG. 12 is a plan view illustrating an intermediate sheet included in the tray of Embodiment 2.

DESCRIPTION OF EMBODIMENTS

Embodiments are described below with reference to the drawings. Common elements in the drawings are denoted by the same symbols, and overlapping descriptions are simplified or omitted. This disclosure may include all the combinations of the combinable configurations out of the configurations to be described in the embodiments below.

Embodiment 1

FIG. 1 is a perspective view illustrating a tray 1 of Embodiment 1. FIG. 2 is a developed view of an outer sheet 2 included in the tray 1 of Embodiment 1. FIG. 3 is a perspective view illustrating one of intermediate sheets 3 included in the tray 1 of Embodiment 1.

As illustrated in FIG. 1, the tray 1 includes the outer sheet 2 made of a cardboard sheet and at least one intermediate sheet 3 made of a cardboard sheet. At least one intermediate sheet 3 is wrapped in the outer sheet 2. The tray 1 of this embodiment includes three laminated intermediate sheets 3. The strength of the tray 1 can be further enhanced by including a plurality of laminated intermediate sheets 3 in the tray 1. The shapes of the plurality of intermediate sheets 3 included in the tray 1 may be the same. Not limited to the abovementioned configuration, the number of the intermediate sheets 3 included in the tray 1 may be one.

At least one recessed portion 13 is formed in an upper surface of the tray 1. In this embodiment, the tray 1 includes 15 recessed portions 13. Objects to be packed such as products can be at least partially accommodated in the recessed portions 13. In this embodiment, the shape of the recessed portion 13 is a rectangle in planar view. The shape of the recessed portion 13 in planar view is not limited to a rectangle and may be a square, a circle, an elliptical shape, or a trapezoid.

The outer sheet 2 includes a bottom wall 4, a first lateral wall 5, a second lateral wall 6, a first upper wall 7, and a second upper wall 8. The first lateral wall 5 is connected to the bottom wall 4 by a first fold line 9. The second lateral wall 6 is connected to the bottom wall 4 by a second fold line 10. The first upper wall 7 is connected to the first lateral wall 5 by a third fold line 11 parallel to the first fold line 9. The second upper wall 8 is connected to the second lateral wall 6 by a fourth fold line 12 parallel to the second fold line 10.

An upper surface of the bottom wall 4 is in contact with a lower surface of the intermediate sheet 3 that is lowermost layer. Lower surfaces of the first upper wall 7 and the second upper wall 8 are in contact with an upper surface of the intermediate sheet 3 that is the uppermost layer.

The shape of the bottom wall 4 in this embodiment is a rectangle. The first fold line 9 and the second fold line 10 are formed along the longitudinal direction of the bottom wall 4.

The shape of the bottom wall 4 is not limited to a rectangle. The shape of the bottom watt 4 may be a trapezoid. In this embodiment, the first fold line 9 and the second fold line 10 are parallel to each other. Not limited to this configuration, the first fold line 9 may be oblique to the second fold line 10.

As illustrated in FIG. 2, the first upper wall 7 has at least one opening 14. In the illustrated configuration, the first upper wall 7 has ten openings 14. The second upper wall 8 has at least one opening 14. In the illustrated configuration, the second upper wall 8 has five openings 14. The opening 14 has a shape corresponding to the recessed portion 13. Each of the openings 14 forms a part of each of the recessed portions 13 in a state in which the tray 1 is assembled.

The outer sheet 2 in this embodiment includes first fastening tabs 15 and second fastening tabs 16. The first fastening tabs 15 are connected to the first upper wall 7 by a fifth fold line 17. The second fastening tabs 16 are connected to the second upper wall 8 by a sixth fold line 18. In the illustrated configuration, there are two first fastening tabs 15, and there are also two second fastening tabs 16. The number of first fastening tabs 15 may be one or three or more. The number of the second fastening tabs 16 may be one or three or more.

The bottom wall 4 has holes 19. In the illustrated configuration, there are two holes 19. In a state in which the tray 1 is assembled, the first fastening tabs 15 and the second fastening tabs 16 are fitted into the holes 19.

In this embodiment, the first upper wall 7 and the second upper wall 8 have shapes that are not symmetrical to each other. The first upper wall 7 is larger than the second upper wall 8. Not limited to this configuration, the shapes of the first upper wall 7 and the second upper wall 8 may be symmetrical to each other.

The shapes of the first upper wall 7 and the second upper wall 8 in this embodiment are rectangles. The shapes of the first upper wall 7 and the second upper wall 8 are not limited to rectangles. The shapes of the first upper wall 7 and the second upper wall 8 may be trapezoids.

The first upper wall 7 has an edge 21 on a side opposite to the third fold line 11. In the illustrated configuration, the edge 21 is parallel to the third fold line 11. Not limited to this configuration, the edge 21 may be oblique to the third fold line 11. The fifth fold line 17 is substantially collinear to the edge 21.

The second upper wall 8 has an edge 22 on a side opposite to the fourth fold line 12. In the illustrated configuration, the edge 22 is parallel to the fourth fold line 12. Not limited to this configuration, the edge 22 may be oblique to the fourth fold line 12. The sixth fold line 18 is substantially collinear to the edge 22.

As illustrated in FIG. 1, the edge 21 of the first upper wall 7 and the edge 22 of the second upper wall 8 are in contact with each other or adjacent to each other in a state in which the tray 1 is assembled.

As illustrated in FIG. 3, the shape of the intermediate sheet 3 in this embodiment is a rectangle. The shape of the intermediate sheet 3 may be substantially the same as the shape of the bottom wall 4. The intermediate sheet 3 has at least one opening 20. In the illustrated configuration, the intermediate sheet 3 has 15 openings 20. The opening 20 has a shape corresponding to the recessed portion 13. The shape of the opening 20 may be the same as the shape of the opening 14. In a state in which the tray 1 is assembled, the following configuration is obtained. Each of the openings 20 forms a part of each of the recessed portions 13. Each of the openings 20 is at the same position as each of the openings 14. The recessed portions 13 are formed by the openings 14 and the openings 20.

The intermediate sheet 3 has holes 23. In the illustrated configuration, there are two holes 23. The intermediate sheet 3 has longitudinal direction edges 24 and 25. In a state in which the tray 1 is assembled, the following configuration is obtained. Each of the holes 23 in the intermediate sheet 3 is at the same positions as each of the holes 19 in the bottom wall 4. The first fastening tabs 15 and the second fastening tabs 16 are fitted into the holes 23 and the holes 19. The longitudinal direction edge 24 is in contact with or adjacent to the first lateral wall 5. The longitudinal direction edge 25 is in contact with or adjacent to the second lateral wall 6.

FIG. 4 is a perspective view illustrating a state in which the tray 1 of Embodiment 1 is being assembled. The tray 1 is assembled as below. First, at least one intermediate sheet 3 is placed on the bottom wall 4 of the outer sheet 2. Then, the first lateral wall 5 and the second lateral wall 6 are folded to the inside along the first fold line 9 and the second fold line 10. Then, the first upper wall 7 and the second upper wall 8 are folded to the inside along the third fold line 11 and the fourth fold line 12. Then, the first fastening tabs 15 and the second fastening tabs 16 are folded to the inside along the fifth fold line 17 and the sixth fold line 18. Then, the first fastening tabs 15 and the second fastening tabs 16 are inserted into the holes 23 in the intermediate sheets 3 and the holes 19 in the bottom wall 4. As a result, the assembling of the tray 1 is finished.

In a state in which the tray 1 is assembled, the following configuration is obtained. The first lateral wall 5 and the second lateral wall 6 are perpendicular to the bottom wall 4. The first upper wall 7 and the second upper wall 8 are parallel to the bottom wall 4. The first fastening tabs 15 and the second fastening tabs 16 are prevented from falling out of the holes 23 and the holes 19 by the frictional force between the outer peripheries of the first fastening tabs 15 and the second fastening tabs 16 and the inner peripheries of the holes 23 and the holes 19. The first fastening tabs 15 and the second fastening tabs 16 are in contact with each other.

According to this embodiment, the following effects are obtained when the logistics transportation or the freight handling is carried out. The intermediate sheets 3 are enveloped in the outer sheet 2, and hence the positions of the intermediate sheets 3 are regulated by the first lateral wall 5 and the second lateral wall 6. As a result, the position misalignment of the intermediate sheets 3 can be reliably prevented. Therefore, the deformation of the tray 1 can be reliably prevented. As a result, a case where the objects to be packed, that is, the products are brought into contact with each other and become damaged can be reliably prevented.

The first fastening tabs 15, the second fastening tabs 16, the holes 19, and the holes 23 are examples of fastening means for fastening the first upper wall 7 and the second upper wall 8. According to this embodiment, the first upper wall 7 and the second upper wall 8 can be reliably fastened by a simple configuration. According to this embodiment, the positions of the intermediate sheets 3 can be fastened by causing the first fastening tabs 15 and the second fastening tabs 16 to be in a state of being fitted in the holes 23 in the intermediate sheets 3. According to this embodiment, the first upper wall 7 and the second upper wall 8 can be more reliably fastened by causing the first fastening tabs 15 and the second fastening tabs 16 to be fitted into the holes 19 in the bottom wall 4 in addition to the holes 23 in the intermediate sheets 3. Instead of this configuration, the bottom wall 4 does not necessarily need to include the holes 19. That is, the first fastening tabs 15 and the second fastening tabs 16 may only be fitted into the holes 23 in the intermediate sheets 3. In addition, instead of the configuration in which all the intermediate sheets 3 include the holes 23, only a part of the intermediate sheets 3 on the upper layer side may include the holes 23.

In this embodiment, the first fastening tabs 15 and the second fastening tabs 16 are fitted into the holes 19 and the holes 23 together. Instead of this configuration, the first fastening tabs 15 and the second fastening tabs 16 may be fitted into separate holes.

The fastening means of the present invention is not limited to the abovementioned configuration. For example, the fastening means may be the following fastening means. The lower surfaces of the first upper wall 7 and the second upper wall 8 may be adhered to the upper surface of the intermediate sheet 3 that is the uppermost layer by an adhesive or a double-faced adhesive tape. First fastening tabs and second fastening tabs having hooks may be connected to the first upper wall 7 and the second upper wall 8, and the hooks of the first fastening tabs and the second fastening tabs may be engaged with the lower surface of the bottom wall 4. Instead, first fastening tabs and second fastening tabs having hooks may be connected to the bottom wall 4, and the hooks of the first fastening tabs and the second fastening tabs may be engaged with the upper surface of the first upper wall 7 and the second upper wall 8.

FIG. 5 is a plan view illustrating a state in which products 90 are fitted in the recessed portions 13 of the tray 1 of Embodiment 1. FIG. 6 is a cross-sectional side elevation view illustrating the state in which products 90 are fitted in the recessed portions 13 of the tray 1 of Embodiment 1. As illustrated in those views, the products 90 that are objects to be packed can be fitted into the recessed portions 13 of the tray 1. The products 90 pass through the openings 20 in the intermediate sheets 3 and come into contact with the bottom wall 4.

FIG. 7 is an exploded perspective view of a packing apparatus 30 including the tray 1 of Embodiment 1. FIG. 8 is a perspective view of a state in which the packing apparatus 30 illustrated in FIG. 7 is assembled. As illustrated in FIG. 7, the packing apparatus 30 includes a plurality of trays 1, a pallet 31, a bottom tray 32, a lateral sheet 33, and a top cap 34. The pallet 31 may be made of wood or plastic. The bottom tray 32, the lateral sheet 33, and the top cap 34 may be made of cardboard sheets.

The packing apparatus 30 is assembled as below. The bottom tray 32 is placed on the pallet 31. The trays 1 are placed on the bottom tray 32. In this embodiment, a plurality of (six) trays 1 can be arranged on the bottom tray 32. The bottom walls 4 of the trays 1 are in contact with an upper surface of the bottom tray 32. The trays 1 in which the products 90 are fitted in the recessed portions 13 are stacked up into a plurality of stages. At this time, the positions of the products 90 on the tray 1 and the positions of the products 90 under the tray 1 matches in the front and rear and right and left horizontal directions. Then, the lateral sheet 33 is placed so as to cover the stacked trays 1. Then, the top cap 34 is mounted so as to cover the upper side of the stacked trays 1. Lastly, as illustrated in FIG. 8, a band 35 is wound around the pallet 31 and the top cap 34 and is fastened. The band 35 may be made of polypropylene.

FIG. 9 is a schematic cross-sectional view of the inside of the packing apparatus 30 illustrated in FIG. 7 and FIG. 8. As illustrated in FIG. 9, in the packing apparatus 30 of this embodiment, the upper surface of the product 90 under the tray 1 and the lower surface of the product 90 on this tray 1 are in contact with each other with the bottom wall 4 of this tray 1 therebetween. FIG. 7 illustrates an example of a case where the shapes of products 91 fitted in the trays 1 in the uppermost stage are different from the shapes of the products 90 illustrated in FIG. 9.

According to this embodiment, the following effects can be obtained. A structure in which the products 90 mainly support the load is obtained. The structure is not affected by a change in strength of the tray 1 due to temperature and humidity. Load shifting due to the deformation of the packing material and the like is less likely to occur.

When the packing apparatus 30 is opened, the trays 1 may be individually removed and moved by hand. At that time, even when the products 90 are heavy, the folding deformation of the tray 1 in the horizontal direction thereof, and particularly the folding deformation in the middle of the tray 1 in the longitudinal direction thereof is less likely to occur. As a result, product damage caused by the products 90 being in contact with each other and the dropping of the tray 1 is less likely to occur.

The products 90 are fitted in the recessed portions 13 of the tray 1, and hence the shock that occurs in the trucking or the freight handling is absorbed by the crushing of the laminated cardboards, and the impact is mitigated. Therefore, the damage of the products 90 is less likely to occur.

As illustrated in FIG. 1, the cardboard sheets of the outer sheet 2 and the intermediate sheets 3 of the tray 1 have flutes having a wave-like cross-sectional shape. The direction in which the flutes extend is parallel to the longitudinal direction of the tray 1. According to this embodiment, the following effects can be obtained by this configuration. The bending strength of the tray 1 in the longitudinal direction thereof is enhanced. The occurrence of the folding deformation of the tray 1 in the horizontal direction thereof, and particularly the folding deformation in the middle of the tray 1 in the longitudinal direction thereof can be prevented more reliably. As a result, the product damage caused by the products 90 coming in contact with each other or the dropping of the tray 1 can be prevented more reliably. Only one of the direction in which the flutes of the cardboard sheet of the outer sheet 2 extend and the direction in which the flutes of the cardboard sheets of the intermediate sheets 3 extend may be parallel to the longitudinal direction of the tray 1. An effect similar to the abovementioned effect can be obtained even in that case.

As illustrated in FIG. 2, in this embodiment, a length L2 of the first lateral wall 5 of the outer sheet 2 in the longitudinal direction thereof is equal to a length L1 of the bottom wall 4 in the longitudinal direction thereof. A length L3 of the second lateral wall 6 of the outer sheet 2 in the longitudinal direction thereof is equal to the length L1 of the bottom wall 4 in the longitudinal direction thereof. According to this embodiment, the following effects can be obtained by this configuration. The bending strength of the tray 1 in the longitudinal direction thereof is enhanced more by the flexural rigidity of the first lateral wall 5 and the second lateral wall 6. The occurrence of the folding deformation of the tray 1 in the horizontal direction thereof, and particularly the folding deformation in the middle of the tray 1 in the longitudinal direction thereof can be prevented more reliably. As a result, the product damage caused by the products 90 coming in contact with each other or the dropping of the tray 1 can be prevented more reliably. Not limited to the illustrated configuration, an effect similar to the abovementioned effect can be obtained as long as the length L2 of the first lateral wall 5 in the longitudinal direction thereof is ½ or more of the length L1 of the bottom wall 4 in the longitudinal direction thereof, and the length L3 of the second lateral wall 6 in the longitudinal direction thereof is ½ or more of the length L1 of the bottom wall 4 in the longitudinal direction thereof.

Embodiment 2

Now, Embodiment 2 is described with reference to FIG. 10 to FIG. 12, but the differences from Embodiment 1 described above are mainly described, and the description of the same parts or corresponding parts are simplified or omitted.

FIG. 10 is a perspective view illustrating a tray 1A of Embodiment 2. FIG. 11 is a developed view of an outer sheet 2A included in the tray 1A of Embodiment 2. FIG. 12 is a plan view illustrating an intermediate sheet 3A included in the tray 1A of Embodiment 2.

As illustrated in FIG. 10, chamfer portions 26 are formed on the corners of the tray 1A of Embodiment 2. In the illustrated configuration, chamfer portions 26 are formed on four corners of the tray 1A. Not limited to this configuration, the chamfer portions 26 may be only formed on one, two, or three of the four corners of the tray 1A. As illustrated in FIG. 11, the outer sheet 2A included in the tray 1A of Embodiment 2 includes cutouts 27. As illustrated in FIG. 12, the intermediate sheet 3A included in the tray 1A of Embodiment 2 includes cutouts 28. The chamfer portions 26 of the tray 1A are formed by the cutouts 27 of the outer sheet 2A and the cutouts 28 of the intermediate sheet 3A.

According to this embodiment, the following effects can be obtained by providing the chamfer portions 26 in the tray 1A. An operator can put his or her fingers in the chamfer portions 26 when the packing apparatus 30 is assembled or when the packing apparatus 30 is opened and the trays 1A are removed, and hence the trays 1A are easily moved and the working property is enhanced even more.

REFERENCE SIGNS LIST

-   1, 1A tray -   2, 2A outer sheet -   3, 3A intermediate sheet -   4 bottom wall -   5 first lateral wall -   6 second lateral wall -   7 first upper wall -   8 second upper wall -   9 first fold line -   10 second fold line -   11 third fold line -   12 fourth fold line -   13 recessed portion -   14 opening -   15 first fastening tab -   16 second fastening tab -   17 fifth fold line -   18 sixth fold line -   19 hole -   20 opening -   21, 22 edge -   23 hole -   24, 25 longitudinal direction edge -   26 chamfer portion -   30 packing apparatus -   31 pallet -   32 bottom tray -   33 lateral sheet -   34 top cap -   35 band -   90, 91 product 

1. A tray comprising: an outer sheet made of a cardboard sheet; at least one intermediate sheet wrapped in the outer sheet, each intermediate sheet being made of a cardboard sheet; and a fastener, the outer sheet including: a bottom wall; a first lateral wall connected to the bottom wall by a first fold line; a second lateral wall connected to the bottom wall by a second fold line; a first upper wall connected to the first lateral wall by a third fold line parallel to the first fold line; and a second upper wall connected to the second lateral wall by a fourth fold line parallel to the second fold line, the fastener being configured to fasten the first upper wall and the second upper wall, and lower surfaces of the first upper wall and the second upper wall being in contact with an upper surface of the intermediate sheet that is an uppermost layer.
 2. The tray according to claim 1, wherein at least one of a direction in which flutes of the cardboard sheet of the outer sheet extend and a direction in which flutes of the cardboard sheet of the intermediate sheet extend is parallel to a longitudinal direction of the tray.
 3. The tray according to claim 1, wherein: a length of the first lateral wall in a longitudinal direction thereof is ½ or more of a length of the bottom wall in a longitudinal direction thereof; and a length of the second lateral wall in a longitudinal direction thereof is ½ or more of the length of the bottom wall in the longitudinal direction thereof.
 4. The tray according to claim 1, wherein the fastener includes a first fastening tab connected to the first upper wall by a fifth fold line, and a second fastening tab connected to the second upper wall by a sixth fold line.
 5. The tray according to claim 4, wherein: the fastener has a hole formed in the intermediate sheet; and the first fastening tab and the second fastening tab are fitted into the hole in the intermediate sheet.
 6. The tray according to claim 4, wherein: the fastener has a hole formed in the intermediate sheet and a hole formed in the bottom wall; and the first fastening tab and the second fastening tab are fitted into the hole in the intermediate sheet and the hole in the bottom wall.
 7. A packing apparatus comprising the tray according to any one of claim
 1. 